Standard 3834 Si Audit Atasat

International Institute of Welding A world of joining experience
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I-6ro:in8 5(e ;ua.i5< and e33e05i:eness o3 /e.din8 =< u5i.i>in8 5(e s5andard ISO 3+34 O=?e05i:e The objective of this publication is to provide companies intending to apply the standard ISO 3834 dealing with the quality management of welding advice on the !ind of procedures and forms that might be beneficial to them and on the content of such procedures" This publication primarily deals with the adoption of ISO 3834#$ but much of the advice is also applicable to ISO 3834#3 and ISO 3834#4" This publication does not mean that all the procedures presented in it are necessarily required" Once the company has thoroughly considered its needs and has decided that it requires a certain procedure this publication can be used in order to find advice for the preparation of the procedure" The publication should not be used as requirements for procedures or chec!#lists in connection with audits"
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This publication is primarily intended for people who are responsible for quality control in the field of welding" %ecause the items presented in this publication may have a significant impact on a company&s business operations and their successful continuation the publication will be a useful tool also for strategic and operational managers" This publication also deals with matters relating to the sale and mar!eting of products" Therefore the sales personnel of welded products shall understand in order to ensure that the products sold are manufactured in accordance with the designs in a controlled manner and with minimal ris!" ISO 3834#' gives the instructions for the selection of the level of quality requirements while ISO 3834#$ 3 and 4 present quality requirements of different
levels" (anufacturers of certain welded products such as pressure vessels offshore structures and steel structures may need to comply with the quality requirements of ISO 3834 required by applicable product standards" )oreign customers may also require compliance with these requirements as well as major e*port companies of their own subcontractors" + company may gain considerable benefit from applying these standards even without third party certification" It is possible to certificate the standard ISO 3834#$ as part of ISO ,--' quality management system or ISO 3834#$ #3 and #4 can be certificated on their own" ISO 3834 presents systematically and comprehensively the factors and measures having an impact on the quality in welding which a company can develop in order to improve the manageability of its production the quality of its products and the reliability of its lead
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International Institute of Welding

A world of joining experience
times as well as the cost#effectiveness of its manufacturing process" )or the company it is important to identify properly those items that will be subject to the requirements presented in ISO 3834#$ 3 and 4" The aim is to avoid unnecessary documentation and procedures and ensure that the quality management is appropriate for the welded products to be manufactured" This publication gives e*amples of the !ey procedures and the related wor! instructions and forms" The !ey issues to be ta!en into account in the quality management of welding0 Te0(ni0a. re:ie/ verifies the company&s capabilities for manufacturing the product that has been ordered and identifies particular welding requirements related to the contract" Only a correctly conducted technical review ensures well#managed ris!#free and cost#effective production" Co-6e5en0e re;uire-en5s s6e0i3ied 3or 5(e /e.din8 6ersonne. will in the case of some wor!shops be clearly different from present practice" 2roduct liability gives additional emphasis on the responsibilities and role of the welding coordination personnel" The requirements relating to qualification of welders and welding operators strengthens the quality management of welding and can also reduce costs caused by errors" The standard may not bring any significant changes to the current practice regarding inspection personnel" Produ05ion 6.an and ;ua.i3ied /e.din8 6ro0edures assure that production is carried out systematically and the characteristics of the welded joints meet the specified requirements" There are several alternatives for the method of qualifying welding procedures and the company shall apply the one that is technically and economically the most appropriate for the product concerned" !es0ri65ion o3 6rodu05ion and 5es5in8 e;ui6-en5 used in connection with welding allows the company to chec! the suitability of its equipment pool for the manufacturing and inspection of the product it sells" +cceptance tests of equipment regular maintenance and possible calibration or validation in order to ensure that it will be possible to follow the welding procedures sufficiently and that the inspection and testing results are reliable" Systematic dealing of non 0on3or-an0es ensures that a defective product is not put into service by mista!e" The reasons for non conformances are analysed and corrective actions carried out in order to prevent similar non conformances in the future" +dopting ISO 3834#$ 3 or 4 requires considerable time and effort by the company with all the personnel being committing to the wor! and the additional activities required0 developing wor! practices performing new duties ensuring the flow of information etc" @hen the implementation starts it might be advantageous to engage e*ternal e*pertise in order to obtain an objective picture of the starting point" The company may decide to focus on reaching a point where the conditions are fit for certification by documentation and procedures for tas!s and activities but the real economic and technical benefit from the adoption of ISO 3834 will be achieved only when the activities and content concerning the welding wor! are developed" )or this reason ISO 3834#$ 3 and 4 should be understood primarily as a tool for developing the welding activities in the company"
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9ontents
2age
'" 4eneral $" .easons for using ISO 3834 3" 9hoice of quality requirement level 4" 2rocedures and forms 4"' 4eneral 4"$ 2urpose and content 4"3 .elevant procedures and formsCchec! lists 4"4 .eview of requirements 4"1 Technical review 4"A Sub#contracting 4"B @elding and associated personnel 4"8 Inspection and testing personnel 4", /quipment 4"'- @elding and related activities 4"'' Storage and handling of welding consumables 4"'$ Storage of parent material 4"'3 2ost# weld heat treatment 4"'4 Inspection and testing 4"'1 5on#conformance and corrective actions 4"'A 9alibration and validation of measuring inspection and testing 4"'B Identification and traceability 4"'8 Duality records 1" 5eed for certification A" +dopting standard 3834 in a company +nne*es + /*ample of chec! list for technical review % /*ample of procedural guidelines for welders& qualification test
4 4 1 A A B 8 ''' '4 'B ', ', $' $$ $3 $4 $1 $B equipment $, 33$ 33
31 3B
1 "enera.
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@elding is a general production method for manufacturing of metal products" @elding has a considerable impact on both the product&s costs and quality" 9onsequently it is important that the welding is carried out as efficiently as possible meeting all specified quality requirements" @eld quality is achieved by sound welding not by inspection" Inspection however provides a chec! of the reliability of the product but cannot improve poor quality" @elding requires continuous control andCor to follow documented procedures" On this basis the ISO 3834 series of welding standards has been prepared" The purpose of the ISO ,--- series is that the company designates as a special process any wor! where the final quality of the product cannot be verified only by inspection" If quality requirements are specified for the welds in the product it is appropriate to define welding as a special process" It shall be observed that ISO 3834 is not a quality control standard that replaces ISO ,--' but more an au*iliary tool for applying ISO ,--' in companies which carry out welding as a special process" In such a case the additional compliance with ISO 3834 will be included by a reference in the ISO ,--' quality system" It is also possible to obtain certification under ISO 3834 without any lin!age to the ISO ,--' quality system" The standards are general and not fi*ed to any certain product" The series of standards refers to three different levels of quality requirements0 # ISO 3834#$ 9omprehensive quality requirements # ISO 3834#3 Standard quality requirements # ISO 3834#4 %asic quality requirements" 4uidance for the choice of level of quality requirements is given in ISO 3834#'" ISO 3834# 1 specifies documents and standards necessary to consider in order to claim conformity to ISO 3834#$ 3 or 4" 2 Reasons 3or usin8 ISO 3+34 .egulations .egulations eg /6 directives define safety requirements on products and structures" 2roduct standards present the technical solutions that serve to fulfil the safety requirements specified in the directives" 2roduct standards (any /uropean and some International product standards refer to the different parts of ISO 3834 regarding welding" )or e*ample the standard concerning pressure vessels E/5 '3441F states that the manufacturer of the pressure vessel is obliged to fulfil as a minimum the welding quality requirements given in ISO 3834#3" The /uropean standard /5 '-,-#$ dealing with e*ecution of steel structures requires the use of quality requirements according to ISO 3834" The level of quality requirements depends on the e*ecution class"
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9ustomers Once ISO 3834 is in use companies could utiliGe it for mar!eting purposes and customers might require certification to ISO 3834" The welding company EmanufacturerF The welding company wishes to improve its welding quality management system increase productivity and by applying quality control in welding demonstrate to its customers to be a reliable supplier" (ain contractors + subcontractor wor!ing to ISO 3834 can e*pect to have a significant advantage over its competitors when a main contractor is outsourcing its welding or welding related activities" ISO ,--' ISO ,--' states that where necessary special processes shall be identified" @elding is typically considered as a special process" This requires that specific requirements which are specified in advance are fulfilled" ISO 3834#$ is an e*cellent tool for doing this" 3 C(oi0e o3 ;ua.i5< re;uire-en5 .e:e. ISO 3834#' gives guidance on the choice of level of quality requirements" @hen a welding company uses a quality control system conforming to ISO ,--' the comprehensive quality requirements according to ISO 3834#$ 3 or 4 may all be selected" There are only small technical differences between ISO 3834#$ and ISO 3834#3" The main difference is the level of documentation" ISO 3834#4 presenting basic quality requirements is the level of choice when the welded components have a low safety ris!" 2roduct standards and national codes may also give references to the different parts of ISO 3834" Table ' gives a short summary of requirements for ISO 3834 in /uropean product standards"
Table ' H Selection of quality requirement level 2roduct or structure Steel structures E/5 '-,-#$F .equirements
/*ecution classes 3 and 4 ISO 3834#$ /*ecution class $ ISO 3834# 3 /*ecution class ' ISO 3834#4
2ressure vessels E/5 '3441F
+t least ISO 3834#3

1
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.ailway vehicles E/5 '1-81F
9ertification level ' ISO 3834#$ 9ertification level $ and 4 ISO 3834# 3 9ertification level 3 ISO 3834#4 ISO 3834#$ .ecommends parts of ISO 3834#$
Off shore E5O.SO<F @ater tube boilers E/5 '$,1$#1F
@hen applying ISO 3834 it should be noted that all of the items presented in the standards do not need to be implemented if they are not relevant" In such cases clear reasons shall be given for such a decision" +s a basis it might be appropriate for a company to start applying the ISO 3834 by adopting the requirements of ISO 3834#$ and identifying those items that are relevant from the companyIs point of view" 9are shall however be ta!en to ensure that the quality requirements specified are not lower than those presented in ISO 3834#4" The company may also apply different levels of quality requirements for different products" +lthough the company may have adopted the standard ISO 3834#$ it may decide to apply lower quality requirements according to ISO 3834#3 or ISO 3834#4 in respect of certain products or certain production lines" 4 Pro0edures and 3or-s 4"' 4eneral
Duality control may be described at three different levels0 +t the general level a description of the company&s organisation areas of responsibility operation equipment personnel etc" is given" +t the procedure level the way in which the activity has to be performed is described as well as responsible persons" +t the level relating to forms the necessary forms lists reports records certificates and detailed wor!ing instructions are prepared" Often the company is not familiar with preparing procedures" The procedures should be as simple as possible" + good procedure fits onto a single +4 sheet and is clear and concise enough to be read without sitting down" 5ot every item needs a procedure" Sometimes it is enough just to !now how things have to be done" It is often difficult to decide whether only !nowing how to do things is enough or whether written procedures are needed" @ritten procedures are needed when people as! a lot of questions different people do the same tas! or when lots of mista!es are made" 4"$ 2urpose and content
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The purpose of procedure is to0

A

ensure harmonised and effective wor!ing establish responsibilities in respect of tas!s and wor! activities act as the practical starting point for preparatory wor! provide information act as a channel for e*changes of e*perience"
2rocedures include e"g0 purpose and scope of the wor! activity what is to be done and who does it Econtent of the procedure and the person responsible for itF when where and how the wor! activity is carried out Econtent of activity person responsible for itF materials equipment and documents that are in use how the wor! activity is managed and documented" 4"3 .elevant procedures and formsCchec! lists
Table $ gives procedures and forms that are appropriate according to different clauses of ISO 3834#$" @here necessary they can also be used when applying ISO 3834#3 and ISO 3834#4" It may not be necessary to apply everything that is presented in Table $J the company has fairly free hands to ma!e the appropriate choices" 6nder no circumstances must the table be used as audit requirements" The procedures provide e*amples of who could be the person responsible for certain wor! activity" The e*amples are completely arbitrary" It is important to nominate the person and ensure that the person is aware of his or her responsibilities and is also given the appropriate power to act"
Table $ H 6seful procedures and formsCchec! lists 9lause 3834#$ in ISO 2rocedure 1"$ 2rocedure for requirement review 1"3 2rocedure for technical review 'F A"' 2rocedure for sub# contracting of welding wor!s A"$ 2rocedure for subcontracting of heat treatment )ormCchec! list 1"$ 9hec! list for assessment 1"$ 9hec! list for assessment A"' )orm for orderingCchec!in g A"$ )orm for orderingCchec!in g
B
1 .eview of requirement review and technical review A Sub# contracting
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contracting of testing and inspection A"4 2rocedure for subcontracting of maintenance A"1 2rocedure for subcontracting of calibration B @elding personnel A"A 2rocedure for B"$ 2rocedure for welders and welding operators $F B"3 2rocedure for welding coordinators B"4 2rocedure for other personnel 8 Inspection and testing personnel , /quipment 8"$ 2rocedures for testing and inspection personnel ,"$" 2rocedure for capacity and capability of equipment ,"3 2rocedure for acceptance of equipment ,"4 2rocedure for starting to use equipment and recording '- @elding and related activities ,"1 2rocedure for '-"'"' 2rocedure for subassemblies '-"'"$ 2rocedure for flow chart '-"$ 2rocedure for preparation of welding procedure specifications '-"3 2rocedure for qualification of welding procedures '-"4 2rocedure for preparation of wor! instructions '-"1 2rocedure for
orderingCchec!ing A"4 )orm for orderingCchec!in g A"1 )orm for orderingCchec!in g A"A B"$ )orm )ile with certificates B"3 )ile with 93 copies of diplomas etc" B"4 )ile 8"$ )ile with copies of qualifications ,"$ 9apacity list ,"3 +cceptance reports ,"4 7ist of equipment ,"1 (aintenance and dimensional reports '-"'"' @elding plan '-"'"$ )low chart '-"$ @elding procedure specifications '-"3 @elding procedure qualification record '-"4 @or! instructions
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'' @elding consumables '$ Storage of parent materials '3 2ost#weld heat treatment
''"3 2rocedure for storage and handling of welding consumables '$ 2rocedure for storage of parent materials '3 2rocedure for preparation of heat treatment procedure specifications '4"$ 2rocedure for activities prior to welding '4"3 2rocedure for control during welding '4"4 2rocedure for final inspection '4"1 2rocedure for preparation of an inspection plan '1"' 2rocedure when the @2S has not been used '1"$ 2rocedure for non# conformances by inspection '1"3 2rocedure for non# conformances found after delivery 'A"' 2rocedures for calibration and validation of thermometers 'A"$ 2rocedures for calibration and validation of electrical measuring devices 'A"3 2rocedures for calibration and validation of measuring devices
''"3 Stoc! list
'$ Stoc! list '3"' ;et treatment procedure specifications '3"$ ;eat treatment records '4"$ 9hec! form '4"3 9hec! form '4"4 9hec! form '4"1 Inspection plan '1"' 5on# conformance report '1"$ 5on# conformance report '1"3 5on# conformance report 'A"' 9alibration and validation report 'A"$ 9alibration and validation report 'A"39alibration and validation report 'B"' (aterial card 'B"$ .outing cards
,
'4 Inspection and testing
'1 5on#conformance and corrective actions
'A 9alibration and validation of measuring inspection and testing equipment
'B Identification and traceability
'A"4 2rocedures for calibration and validation of 'B"' 2rocedure for mar!ings 'B"$ 2rocedure for transfer of mar!ings 'B"3 2rocedure for
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identification of welders 'B"4 2rocedure for acceptance tests '8 Duality records
'F
/*ample see anne* +
'8 2rocedure for preparing and filing of $Fquality records
'8 .ecord forms
/*ample see anne* % 4"4 .eview of requirements The procedure for conducting the review of requirements concerns the part of the contract that deals with welding" The purpose of the review is to ensure0 that the company is technically and otherwise capable Ee"g" delivery scheduleF to fulfil all the requirements and wishes presented by the customer and to chec! that all the fundamental requirements relating to the welding of the product are recorded" The review of requirements shall be conducted before any offer is submitted" The review of requirements is the responsibility of the person e"g" sales manager or project manager who goes through the orders and the proposed contract" It is important for the welding coordinator to be present when matters concerning welding in the contract are dealt with" If there are ambiguities in the order or in the proposed contract the person in charge solves them together with the other parties and with the customer" In the review of requirements the relevant items presented in clause 1"$ in ISO 3834#$ are reviewed" It is useful to draft a form for dealing with the matters below" If the company has previously supplied an identical or similar product it is not essential to complete the form in respect of each individual contract" aF 2roduct standard to be used together with any supplementary requirements0 does the product relate to any directiveK does a product standard e*ist Ee"g" ISO# /5# or national standardFK does the customer have an e*isting product standardK quality level and acceptance criteriaK the mechanical thermal andCor chemical characteristics set for the welded joints any additional requirementsK bF Statutory and regulatory requirements does the product relate to any regulationK cF +ny additional requirement determined by the manufacturer any additional requirementsK dF The capability of the manufacturer to meet the prescribed requirements new projectK
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review of resourcesK 4"1 Technical review The purpose of the procedure for the technical review is to loo! at the matters that shall be ta!en into account when reviewing the contract" The procedure deals with matters concerning welding" /ach company has to nominate the person who will ta!e responsibility for these matters" That person may be for instance the main project designer" The welding coordinator shall be present whenever any welding matters are discussed" The following issues should be resolved before the procedure is prepared0 has a technical review been conducted previously Ehave earlier e*periences been ta!en into accountFK what are the differences in relation to previous requirementsK Eany fundamental changesKF The technical review should cover at least the matters presented in clause 1"3 of ISO 3834#$ as described in the list below" If the product in question has been manufactured in the past it is not always necessary to review these matters again" aF Specification of parent materialEsF and welded joint properties0 weldability chemical composition strength ductility Eimpact tensileF thic!ness of material corrosion resistance wear resistance high temperature characteristics quality of parent material surface other characteristics bF Duality and acceptance requirements for welds0 quality level acceptance level acceptance criteria for welding tests cF 7ocation accessibility and sequence of welds including accessibility for inspection and for 5:T0 appropriate welding positions welding equipment being used including feasibility of automated welding significance of the welding sequence due to distortion of the wor! piece at which stage of manufacturing shall inspection be performedK d'F @elding procedures0 do all necessary welding procedure specifications e*istK are welding procedure specifications required for all the jointsK
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d$F @ritten procedures for non#destructive testing E5:TF0 will non#destructive testing E5:TF be conductedK will the company perform the necessary non#destructive testing itselfK do the necessary written procedures e*ist e"g" 5:T standards for the 5:T methods to be performedK d3F ;eat#treatment procedures0 are procedures needed for pre#heating andCor post#welding heat treatmentK will the company perform the necessary pre#heatingCheat treatment itselfK are there appropriate procedures for pre#heatingCheat treatmentK eF The approach to be used for the qualification of welding procedures0 how should the welding procedures be qualified Ee"g" ISO '1A-BFK additional requirements Ee"g" product standardsFK acceptance criteria for the welding procedure test are there any appropriate qualification records availableK fF Dualification of personnel0 is there a responsible welding coordinatorK do the welders have valid certificates for the job in hand according to ISO ,A-AC/5 $8B or other applicable standardsK +re additional requirements necessary Ee"g" product standardsFK are the welding operators qualified according to ISO '4B3$C/5 '4'8 or other applicable standardsK are the 5:T inspectors certified according to ISO ,B'$ or /5 4B3 are there any requirements for qualification of persons carrying out heat treatmentK g'F Selection of material identification andCor traceability0 what is the parent materialK availabilityK weldabilityCspecial characteristicsK supplier approvedK !nownK how is the parent material identified Etransfer of mar!ingFK should the parent material used in the product be traceableK are material certificates requiredK Ewhat levelKF approved parent materialCfiller material filler materialK Etest reportsKF g$F Selection of welders0 does the wor! require a welder who has a valid certificate for that particular welding jobK g3F Identification of welds0 do the welds have to be identifiableK Eto the welderKF hF Duality control arrangements including any involvement of an independent inspection body0 is e*ternal quality control required during manufactureK # customerK # third partyK # whenK
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'$

iF Inspection and testing0 which parts will be inspected or testedK # scope of inspection # inspection methods # inspection stages # reporting level Eeverything deviations errorsF jF Sub#contracting0 welding wor! Erequired competences and licencesF 5:T testing post#weld heat treatment does the customer approve the sub#contractorK how should sub#contractors be auditedK previous e*perience of sub#contracting approved suppliers !F 2ost#weld heat treatment0 has the company ta!en into account the quality requirements presented in ISO 'BA33 concerning heat treatment in connection with weldingK lF Other welding requirements0 production weld tests batch testing of welding consumables determination of ferrite content of weld metal ageing hydrogen content sufficient information on permanent bac!ing peening surface finish weld profile Eundercuts smooth transition shape of root conve* weld EgrindingF welding plan mF 6sing special methods0 root opening root gas buttering nF dimensions and details of joint preparation on completed weld0 type of joint type of joint preparation groove preparation tolerances oF @elds which are to be made in wor!shop or elsewhere0 where final installation ta!es place Eon siteFK are the components produced in different wor!shopsK pF /nvironmental conditions relevant to the application of processes0 low temperature wind
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'3

moisture lightening qF ;andling of non#conformances0 how to act in case of a non conformanceK # additional inspections Ecan the number of inspections be reducedKF # alternative inspection methods how to proceed if modifications are required after the contract stageK # who is authorised to approve the changesK # documentation of changesK 4"A Sub#contracting If the company intends to use sub#contracting services Ee"g" in welding inspection 5:T heat treatment calibration maintenanceF he shall provide the subcontractor with all the relevant specifications and requirements" The sub#contractor shall provide the documents and records specified by the manufacturer concerning the sub#contracted wor!" 4"A"' Sub#contracting of welding The procedures on sub#contracting shall ensure that the sub#contractor has the technical and qualitative capabilities Ecapacity and !now#howF to manufacture the product such that the product meets the requirements specified by the actual customer comply with the appropriate items of ISO 3834 and that the timetable requirements will be met" The person responsible for the sub#contracting matters of the company has the responsibility to ensure that the sub#contractor meets the technical preconditions required of manufacturing" This person should use e*perts in the company e"g" the responsible welding coordinator" Scope of sub-contractor assessment Only the part of the subcontractorIs technical !now#how has to be assessed as required for the sub#contracting wor!" The scope of the assessment depends on what !ind of quality system the sub#contractor has in use" If the subcontractor wor!s according to a certified quality system including ISO 3834#$ it will be enough just to conform the technical competence EcapacityF and to chec! the equipment" + sub#contractor without any documented quality system should be subjected to a separate quality audit conducted by the company" Items to be addressed with the sub-contractor Re:ie/ o3 re;uire-en5s + review of requirements with the sub#contractor may be performed together with the technical review" + review of requirements may include the following" aF 2roduct standard and possible additional requirements to be applied0
SI./T 0 4$$ 331 ,-' ---', # +2/ 1$4. # T3+ 0 ).$-4$$331,-'
'4

the sub#contractor needs to !now what standard and requirements the product has to fulfil" Te0(ni0a. re:ie/ + technical review shall be performed with the sub#contractor wherein all the essential aspects related to the sub#contractorIs wor! will be addressed" 9onsideration should also be given to any earlier technical reviews or similar reviews" If there is significance differences or changes in resources of the sub#contractor an assessment is necessary" + technical review may include the following" 1@ 4e.din8 6ro0edure s6e0i3i0a5ions) The sub#contractorIs welding procedure specifications need to be chec!ed" If they are not suitable for the product to be welded the sub#contractor shall qualify new welding procedures to comply with the product and based on these qualifications new welding procedure specifications shall be prepared" +ssessment to be made whether it is possible to use the main companyIs welding procedure specifications Estandard proceduresF 2@ Non des5ru05i:e 5es5in8 6ro0edures) @ill 5:T be performed and if so what is the e*tentK @ill this be done0 # by the sub#contractor # by the company itself # by a testing company chosen by the sub#contractor # by the testing company used by the main company which will also inspect the main companyIs own manufacturing # for which authority shall the results be presented and who will present themK 3@ ea5-5rea5-en5 6ro0edures) Is heat treatment neededK @ho will be the e*pert for heat treatment0 The main company or the sub#contractorK 4@ 9ua.i3i0a5ion o3 /e.din8 6ro0edures) The sub#contractorIs welding procedures shall be qualified by the method required by the quality requirements of the product to be manufactured 5@ 9ua.i3i0a5ion o3 6ersonne.) +re the qualifications of personnel adequate or does the sub#contractor&s personnel need new qualifications for the product to be manufactured eg welders and welding operatorsK ;as a responsible welding co#ordinator been nominated and what is his tas!K Is the responsible welding co#ordinator employed by the sub#contractorK 6@ Aa5eria. :oes the main company deliver materials to the sub#contractor and how are these identified and separated from the subcontractorIs own materialsK If the subcontractor buys the material the following need to be specified0 # Type of material Ee"g" standard composition dimensional tolerances etc"F"
SI./T 0 4$$ 331 ,-' ---', # +2/ 1$4. # T3+ 0 ).$-4$$331,-'
'1

# Duality requirements for materials # +pprovals material certificates required # .equirements for identification and traceability of the material ,@ Se.e05ion and iden5i3i0a5ion o3 /e.ders) @here necessary the same level as applied by the main company +@ Ins6e05ion and 5es5in8) The sub#contractor needs to be informed about what !inds of destructive and non destructive testing is required and what the quality requirements are for the product manufactured by the sub#contractor 9ustomer&s inspections Inspections performed by others Eis there a quality planKF 9@ Pos5-/e.d (ea5 5rea5-en5) If the product requires post#weld heat treatment it is necessary to agree how the sub# contractor deals with post#weld heat treatment and on the quality requirements 10@ O5(er re;uire-en5s re.a5ed 5o /e.din8) The sub#contractor must be provided with all the necessary information in order to be able to do the required wor! 11@ and.in8 o3 non-0on3or-an0es) @hat to do and who ma!es the decisions concerning non#conformancesK @ho conducts possible necessary negotiations with the main customer and as necessary with the authorities Eor equivalentFK 12@ O5(er in3or-a5ion Design data The sub#contractor shall be provided with clear wor!shop drawings and instructions such as the following0 material bac!ing details and dimensions of joint preparations permitted welding processes and consumables where necessary welding sequence specification of parent material and characteristics of welded joints quality of the welds and acceptance requirements possible special instructions Quality records @hen required by the main company the subcontractor shall provide or present documents such as the following0 @elding procedure specifications @elding procedure qualification records @eldersI qualification test certificates (easurement records
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'A

Test reports from 5:T and possible destructive testing .ecords of repairs and other non#conformance reports :ocuments related to the delivery
The quality documents to be filed either by the sub#contractor or by the main company as agreed" 4"A"$ Sub#contracting of heat treatment +n assessment of the sub#contractor will be performed during which the items listed in clause 4"'3 will be chec!ed" 4"A"3 Sub#contracting of inspection and testing +n assessment of the sub#contractors will be performed during which the items listed below will be chec!ed" aF Sub#contractor&s competence +re there any requirements for accreditationK bF Inspection plan See clause 4"'4"1 cF Dualification of 5:T personnel EISO ,B'$ or /5 4B3F 4"A"4 Sub#contracting of maintenance wor!s +n assessment of the sub#contractor will be performed during which the items listed in clause 4","1 will be chec!ed" 4"A"1 Sub#contracting of calibration +n assessment of the subcontractor will be performed during which the items listed in clause 4"'A will be chec!ed" 4"B @elding and the associated personnel
4"B"' 4eneral The purpose of the procedure is to ensure that the company has the required competent personnel capable to fulfil the tas!s required by the contract by the regulatory requirements and by codes and orders of other bodies concerned" The procedures apply to qualification of personnel and their various tas!s"
SI./T 0 4$$ 331 ,-' ---', # +2/ 1$4. # T3+ 0 ).$-4$$331,-'

'B

The responsibility for the s!ill of the personnel can for e*ample be allocated to the company&s ;. manager or production manager" In the welding matters the responsible welding co#ordinator will be contacted" +t technical reviews personnel required for various projects are discussed along with their qualifications" 4"B"$ @elders and welding operators Those doing welding wor! are required to be qualified according to the relevant part of ISO ,A-A#' or /5 $8B ISO '4B3$ or /5 '4'8 unless otherwise required by the product standard or in the contract" The procedures show how qualifications and possible renewal including possible special requirements are to be dealt with" In some cases a production test on site is required before the welder can start to wor!" The welderIs job description could also include the following activities0 joint preparation Eaccording to instructionsF fitting Eaccording to instructionsF maintenance Eaccording to instructionsF" 4"B"3 @elding coordinator The company shall nominate at least one welding coordinator EresponsibleF who has the overall welding responsibility and the necessary authorisations Ee"g" to stop productionF" It is possible for one responsible welding coordinator to be responsible for several sub# contractors" If the field of activities of the company is broad the tas!s can be shared e"g" between the lead welding coordinator and other welding coordinators or welding foremen" @here necessary the welding coordinators and welding foremen report to the lead coordinator" The qualifications of the welding coordinators need to be demonstrated through sufficient e*perience or training Ee"g" II@F" ISO '4B3' shall be ta!en into consideration for the choice of welding coordinatorsI tas!s" Res6onsi=.e /e.din8 0oordina5or Eoften the only welding coordinator in a companyF @hen defining tas!s for the responsible welding coordinator the following list can be used as guidance Esee also ISO '4B3'F0 Organising of welding quality management according to ISO 3834 9oordination of qualification of welding procedures 6pdating and distribution of files with welding procedure qualification records 2reparation and signing of welding procedure specifications 2ublication of a table with qualified welding procedure specifications 4eneral instructions for weldersI qualification 6pdating and publication of a centralised welder register /*pert tas!s connected to purchasing of welding equipment and materials 9oordination of welderIs training Training of e*aminers for welderIs qualification tests
SI./T 0 4$$ 331 ,-' ---', # +2/ 1$4. # T3+ 0 ).$-4$$331,-'
'8

Technical welding e*pert services for different departments and units in the company Eincluding the :esign :epartment and .equirements .eviewF" @here necessary a competence requirement may be specified for the responsible welding co#ordinator Ee"g" I@/CI@TCI@SF" 4e.din8 0oordina5or Ecan also be responsibleF @hen preparing procedures for assisting welding coordinators the following list can be used as guidance Esee also ISO '4B3'F0 :epartment#specific organising and preparation of procedures and forms concerning quality management in welding +cting as the responsible welding coordinator of various projects ;aving welding tests done according to the needs of the department 2reparing and releasing of welding and heat#treatment procedure specifications to be used /nsuring functioning of weldersI qualification systems @elders& training nominating of personnel for transfer mar!ing on materials 9ontrolling validity of weldersI qualifications 9ontrolling to ensure that transfer of mar!ings ta!es place according to instructions .eserving of welding equipment .eserving of welding consumables @here necessary a competence requirement may be specified for the welding coordinator Ee"g" I@TF" 4e.din8 3ore-an + welding foreman&s tas!s include0 @or! planning Organising and control of welding wor! /nsuring welding is carried out in accordance with @2S Organising and control of heat treatment Organising and control of inspections" @here necessary a competence requirement may be specified for the welding coordinator Ee"g" I@SF" 4"B"4 Other personnel Enot in ISO 3834F Designer :esigners tas!s include e"g"0 2reparation of manufacturing and welding drawings :esign of welded joints 2reparation of prefabrication drawings
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',

:etermination of manufacturing tolerances and appropriate choice of reference points and reference levels for dimensioning" eat-treatment personnel The heat#treatment operator&s tas!s include e"g"0 ;eat treatment according to specifications 9alibration of temperature measuring and recording equipment 3alidation of the furnace controlled temperature Gone 9ontrol of temperatures :ocumentation of heat treatments 7oading supporting protection installation of measurement sensors insulators and heating elements" 4"8 Inspection and testing personnel The purpose of the procedure is to ensure that the qualifications of the 5:T personnel are of a required level and in accordance with the ISO ,B'$ or /5 4B3 or as specified in the product standard or contract" 4", /quipment 4","' 4eneral The purpose of the procedures is to ensure that the welding equipment can be used as required by the welding procedure specifications" :efective equipment shall not be used" The procedures apply to description acceptance use and maintenance of equipment" (achine cards shall be !ept of each equipment item showing the following0 Type and capacity (anufacturer and machine number (achine number used by the company or some other unique mar! +cceptance tests .egular maintenance" The responsibility for the maintenance of the equipment could be given to the maintenance manager or service manager" The responsibility may also be delegated to users" 4","$ 2rocedure for capacity and capability of equipment The procedure dealing with the description of the equipment shall specify what the capacity list includes e"g" number and capacity of welding equipment such as ma*imum welding current"
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$-

4","3 2rocedure for acceptance of equipment %efore equipments are accepted it may be necessary to perform an acceptance test" If no acceptance standard is available the necessary procedures may be prepared together with the equipment supplier" 4","4 2rocedure for starting to use equipment and recording %efore the use of new or refurbished equipment the following chec!s are necessary0 /*ternal integrity 9ondition of cables Operating functions" )urthermore a welding test should be performed to ensure that the equipment functions normally" 4","1 2rocedure for maintenance of equipment aF (aintenance interval responsible person and the person performing the maintenance" The maintenance report of a welding machine may show the following for e*ample0 Inspections related to electrical safety 9ondition of welding cables 9ondition of wire feeding devices 9ondition of welding gun or welding torch Output capacity 9ondition of measuring devices" bF In daily maintenance of welding machines the following shall be observed0 9ondition of wire feed roller and correct compressive force 9ondition of current and gas noGGles 9ondition of insulator sleeve of gas noGGle 9ondition of protection hose of welding gun 9ondition of earthing 4as flow of shielding gas 9ondition of valves"
4"'-
@elding and related activities
The purpose of the procedures is to ensure that welding and the related activities ta!e place as planned" The responsibility for welding activities may be given to the responsible welding coordinator production manager manufacturing manager or the welding foreman"
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$'

The procedures may apply to the production plan preparation and qualification of welding procedures preparation of wor! instructions maintenance wor! and au*iliary wor! daily planning and performance of welding maintenance or supporting activities" 4"'-"' 2rocedures for preparing the production plan ISO 3834#$ can be applied as such for procedures concerning the production plan" Separate procedures could be prepared for individual wor! stages e"g" cleaning nestling joint preparation post#weld treatment and inspection of welds" + routing card can also be used to assist the preparation of the production plan" 4"'-"$ 2rocedures for preparation of welding procedure specifications The procedure for preparing of welding procedure specifications may include the following0 @hich items shall be included and to what degree of accuracyK Tolerances Efor joint preparationsJ for welding parametersF )or which products may the procedures be usedK (ethod of qualification 9hoice of welding consumables Ebased on performed tests e*perience or customerIs requirements ta!ing into account additional recommendations given by the consumable manufacturer and possible authority requirementsF @ho has the right to sign welding procedure specificationsK Special procedures # 9leaning # tac!ing # buttering # root opening # pre#heating Emeasurement according to ISO '3,'AFK # repair welding" 4"'-"3 2rocedures for qualification of welding procedures The preparation of welding procedure qualification records E@2D.F shall be included in the procedure for qualification of welding procedures" aF The @2D. for qualification by tested welding consumables EISO '1A'-F may be based on the following0 inspection bodyIs Ee"g" TT< TL3 :53 7loyds etc"F lists of parent materials and filler materials welding consumable manufacturer&s list Ee"g" /sab /lga %Mhler etc"F which may include filler material specific approvals" bF The @2D. for qualification by previous e*perience EISO '1A''F may consist of the following0 Test reports and
SI./T 0 4$$ 331 ,-' ---', # +2/ 1$4. # T3+ 0 ).$-4$$331,-'
$$

9ustomerIs statement that the product has been in use the last five years without any need for weld repair" This statement may be done e"g" in connection with maintenance at the customer" cF Standard welding procedure EISO '1A'$F0 @2D. prepared by the organisation which performed the welding procedure test Eif availableF" dF @elding procedure tests EISO '1A'4F and pre#production tests EISO '1A'3F0 2rocedures for e*amination of tests Ewhat to do before during test and after the testsF Inspection and test reports" The signatory of the qualification will be nominated in all cases" 4"'-"4 @or! instructions The procedure for preparing of wor! instructions may include the following0 @hich items of the welding procedure specification and to what e*tentK @ho has the right to sign the wor! instructionsK @ho may use wor! instructionsK 4"'-"1 2rocedure for welding maintenance and supporting activities The welder shall be able to understand the maintenance procedures Edaily maintenance and periodic maintenanceF for the equipment and its parts" See clause 4","1" 4"'' Storage and handling of welding consumables The purpose of the procedure is to ensure that the handling and storage of welding consumables has been sufficiently addressed in order to prevent them from becoming moist o*idised and damaged or mi*ed with one another" The procedure for storage drying ba!ing and handling needs to comply with the recommendations of the manufacturer of welding consumables" Res6onsi=i.i5< The person responsible for the storage and handling of the welding consumables is the person in charge of welding in the company e"g" responsible welding coordinator or a person authorised by the coordinator e"g" the stoc! !eeper" Con5en5s The procedure for storage of welding consumables may include the following0 aF Sufficiently detailed information for ordering welding consumables0 Is it enough to use the classification and then choosing other welding consumables with the same classificationK Is it mandatory to purchase only welding consumables with specific trade namesK Is in special cases a material certificate necessaryK
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$3

bF +cceptance of welding consumables0 9onforming that the purchased welding consumable is what was ordered 9hec! that sufficient mar!ings are in place" cF Storage of welding consumables0 Temperature range in the storehouse shall be defined /*isting ma*imum relative humidity in the storehouse shall be defined @here necessary other conditions in the storehouse shall be reported 9onsumables to be stored in unopened original pac!ages and opened pac!ages always to be used first Sequence of giving out of consumables from the storehouse0 oldest consumables to be used first Efirst in first outF The number of consumables that can be given out from the storehouse for use at the wor! place shall be specified" dF ;andling of welding consumables0 The consumables shall not become mi*ed up during use @here necessary they shall be mar!ed e"g" with stic!ers or coloured mar!ings @here necessary the welding consumables shall be dried @here necessary holding ovens or quivers shall be used @here necessary the ma*imum storage time at the wor! place shall be specified after which the consumables need to be re#dried or scrapped + minimum number of opened pac!ages shall be permitted at the wor! place 2roper discipline required on the wor! place0 e"g" covered electrodes shall not be left around" eF :rying and storage of welding consumables0 :evices used for drying need to be available 9onsumable specific instructions for drying based on the manufacturerIs instructions Etemperature and drying timeF shall be given The ma*imum holding time in holding oven shall be ta!en into account (i*ing of welding consumables shall not be possible" 4"'$ Storage of parent materials
consumable
The purpose of the procedure is to ensure that the parent materials used for welded products meet the requirements specified for the product" The procedure applies to the storage and handling of the parent materials" The person responsible for manufacturing in the company is responsible for the storage of parent materials" The person responsible organises and ensures that the storage of parent materials does not cause damage or that they become mi*ed during storage" It is important to prevent wrong materials from being used" Con5en5s The requirements specified for a product or by a contract or a standard or the authorities shall be observed in the identification of materials"
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$4

aF If the material supplier provides or is required to provide an order confirmation this shall be chec!ed with care and e*pertise also in regard to its technical part" bF 9are shall be ta!en during acceptance inspections to ensure that all of the requirements in the order have been fulfilled and that all of the mar!ings are as required" cF 9are shall be ta!en in the storage that the materials will not be damaged or mi*ed up" dF In nestling care shall be ta!en in mar!ing to ensure that the materials will not become mi*ed up" The mar!ing system shall correspond to the product standards" (ar!s made using crayons paint or stamps or batch#specific identifier cards may be used as necessary" )or e*ample the transfer of the mar!ings of the pressure vessel materials shall be made before nestling" + person appropriately trained will transfer the following mar!ings0 (aterial quality 9ast and test numbers Stamp of the person transferring the mar!ings" Small parts may be mar!ed using code mar!ings" eF :uring manufacturing care shall be ta!en to ensure that the identification of the materials is retained" fF @here necessary and according to the product standard the customer shall be provided with information about the materials used and as necessary also with material certificates" 4"'3 2ost#weld heat treatment
The purpose of the procedure is to ensure that the welds are heat#treated in a specified manner in order to fulfil the requirements of the welded product" The procedure applies to the heat treatment after welding" The responsibility for the heat treatment can be allocated to the person responsible for manufacturing or to the welding co#ordinator" Con5en5s ISO 'BAA3 describes heat treatment as a special process" It includes the following0 .eview of requirements and technical review Subcontracting 2ersonnel Inspection and testing /quipment for heat#treatment ;eat treatment activities ;eat treatment records 5on#conformance and corrective actions Duality records
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$1

4"'4
Inspection and testing
421421 Con5en5s The purpose of the procedure EInspection and Testing 2lanF is mainly to ensure that quality control is in place before welding during welding and after welding" 2rocedures are prepared for visual inspection and for both destructive and non# destructive testing" The overall responsibility for inspections lies with a person who is independent of production e"g" the quality manager" The person or organisation performing the inspection is responsible for the actual inspection wor! and its results" The inspectorsI visual acuity should be chec!ed at regular intervals" The majority of inspections do not require an outside inspector e"g" a welder trained for inspection tas!s can do the visual inspection of the welds he has made" The general principle is that the person doing the wor! is responsible for that wor!" 4"'4"$ Inspection and testing before welding The procedure may include0 aF Inspection of the welder&s qualifications0 3alidity Suitability Erange of qualificationF bF @elding procedure specificationsCwor! instructions0 5ecessity Suitability 9orrect welding procedure specification 2arent material and material thic!ness Identity of parent material @elding consumableEsF Emar!ing storage and conditionF :imensions of joint preparations Emethod of preparation bevel angle gap depth of root faceF )it#up jigging and tac!ing Setting of welding parameters Ewelding current voltage wire feed rateF (easurement of preheating temperature /nvironmental conditions Ee"g" temperature and draughtF cF 2roduction tests0 /*tension parts to be welded for destructive testing dF 5on#conformances 4"'4"3 Inspection during welding The procedure may include0
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$A

aF 9ontrol of welding parameters Ethat they are in useF0 @elding current +rc voltage Travel speed 4as flow rate 9ontact tube distance bF Temperature measurements0 ISO '3,'A may be used when measuring the pre#heating temperature the interpass temperature and preheat maintenance temperature" cF 6se and handling of welding consumables dF 9leaning shape and number of runs eF @elding sequence fF %ac! gouging gF 9ontrol of distortion hF .equired intermediate e*aminations iF 5on#conformances 4"'4"4 Inspection after welding The procedure may include0 aF Implementation of the testing plan Edestructive and non#destructive testingF bF 9hec!ing of test reports0 @ritten instructions Ee"g" a specific standardF +cceptance levels Dualifications of inspection personnel cF 9hec!ing the shape profile and dimensions of the structure dF .esults of post#treatment0 4rinding 2ost#heating#treatment record +geing eF 5on#conformances Sometimes there could be a need to prepare testing plan EIT2F" It might include0 Test object /*tent of testing Testing time Test methodsCequipment Subcontracting Test instructions Testing conditions Ee"g" lighting viewing angle viewing distanceF
SI./T 0 4$$ 331 ,-' ---', # +2/ 1$4. # T3+ 0 ).$-4$$331,-'
$B

+cceptance levels Ee"g" corresponding to quality levelsF

.ecording instructions or report forms"
4"'4"1 Inspection and testing status The inspection or test status of the welded structure is given in an appropriate manner e"g" by means of a mar!ing on the object itself or a traceability card" 4"'1 5on#conformances and corrective actions
The purpose of procedures is to ensure that a nonconforming product does not go forward into production for use or to be delivered to the customer correction is ta!en to correct the nonconformance corrective actions are ta!en to avoid repetition of the fault" The procedures concern welding inspection and non#conformances found after delivery" It is important to define what a non#conformance is" +ll parties are obliged to report of any non#conformance they have noted" :epending on the nature of the non#conformance the welder shall have the right if necessary to interrupt hisCher wor!" + designated person shall be given the responsibility for ensuring that the correctionsCrepairs are made according to instructions and completed and that the required quality has been reached" 4"'1"' 2rocedures when the welding procedure specification has not been followed or is impossible to follow If the welding procedure specificationsCwor! instruction was not followed the welder shall inform e"g" the foremanCresponsible welding coordinator about it" + non#conformance report shall be made of this type of non#conformance" The contents of the report should include e"g" of the following items0 :escription of the non#conformance 2roposed action Ecorrection of welding procedure specifications instructionsKF :ecision 9ontrol of implementation 9orrective action" The procedure should describe how to proceed e"g" aF 5o action bF 9orrection without permission cF 9orrection with permission from a certain person dF 9lassification for alternative use eF Scrapping"
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or
wor!
$8

+ny repair welding shall be done according to the qualified welding procedures" 4"'1"$ 2rocedures for non#conformances found during inspection The following may be mentioned in procedures for how to handle weld imperfections found during inspection0 The way in which the imperfection has to be mar!ed +cceptance of the non#conformance Increasing the e*tent of testing and additional test methods Esee technical reviewF corrective actions Esee technical reviewF reporting Esee 4"'1"'F" 4"'1"3 2rocedures for non#conformances found after delivery 2rocedures for dealing with non#conformances found after delivery may include the following0 9lassification of the non#conformance 5:T ;eat treatment :oes the welding procedure specification really meet the requirements for the wor! to be doneK ;as the welding procedure specification been wrongly preparedK ;as the welding procedure specification been qualified by previous welding e*perience according /5 ISO '1A'' Ethe qualification of @2S to be withdrawnKF @hat method has to be followed in corrective and preventive actionsK .eporting Others 4"'A 9alibration and validation of measuring inspection and testing equipment The purpose of the procedures is to ensure that the measurement instruments and equipment in use meet the required technical and other criteria for fulfilling the requirements specified by the customer" .equirements for calibration and validation of equipment used for welding including ancillary activities are given in ISO 'BAA$" The procedures refer to the measurement instruments and equipment used in manufacture and inspection" The company shall nominate a person responsible for calibration and validation" The company is responsible for the appropriate calibration or validation of inspection measurement and testing equipment for welded products" The e*tent and level of accuracy of the calibration or validation and the interval between these activities shall be defined by the company according to required product standards" It shall be observed that tight production tolerances cause a greater need for accuracy of calibrated or validated equipment" 4enerally calibration concerns instruments and equipment Emaster instrumentsF used for validation of instruments used in testing the final properties of a product" )or products requiring great accuracy the degree of measurement uncertainty EaccuracyF shall be !nown and it is necessary to ensure the company&s own measurement equipment is traceable to international measurement standards"
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$,

The company shall prepare the necessary calibration or validation procedures for instruments and equipment" The most common objects of calibration or validation in the welding industry include0 aF The equipment required for inspection by measuring of finished products or if necessary parts e"g"0 measuring tapes for final inspections caliper gauges and micrometers gauge bloc!s dial indicators angle gauges measuring instruments for throat thic!nesses rulers matrices thic!ness gauges theodolites and measuring machines bF cF 4auges and meters used in welding and flame cutting e"g"0 ammeters and voltmeters tachometers gas flow meters ErotameterF wire feed regulator measurement equipment required in heat treatment and pre#heating e"g"0 plotters regulators thermoelements thermometers pyrometers
dF /quipment used in non#destructive testing e"g"0 magnetiGation equipment magnetic field gauge light intensity meters ?#ray equipment viewing devices densitometers ultrasonic equipment and calibration bloc!s eF :estructive testing0 The equipment should be subject to official calibration inspection e"g" hardness tensile testing machines and impact hammers" 4"'B Identification and traceability
The purpose of the procedures is to ensure that the identification and traceability of the welded product or its parts are maintained throughout the whole manufacturing process"
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3-

The procedures concern organiGing and documenting the identification and traceability of welding and related activities" The company is responsible for planning managing and documenting identification and traceability at the product level" Identification and traceability relating to welding should include if necessary depending on the structure and its application0 identification of production plans Esee also clause 4"'-"'F identification of routing cards or a list identification of weld locations e"g" by a drawing of the actual situation identification of non#destructive testing procedures and personnel Efor which objectKF identification of welding consumables e"g" designation trade name manufacturer of welding consumables and batch or cast number if required identification andCor traceability of parent material e"g" type cast number if required identification of location of weld repairs identification of location of temporary attachments traceability for fully mechaniGed or automatic welding units to specific welds traceability of welders and welding operators to specific welds " traceability of welding procedure specifications to specific welds" 4"'8 Duality records
421+21 "enera.
The quality records are an essential part of the company&s quality assurance system" They provide the basis for its quality policy quality objectives and wor!ing methods and they ensure the repeatability of procedures" @ith the help of the quality records and systematic wor!ing methods it is possible to get customers and possible third parties already interested at the first contact" +t the same time they may also be convinced of the company&s ability to manufacture and deliver the required product" The records should be used by all those whose wor! is affected by the document in question" The quality records can be divided into two groups0 'F The documents relating to the company&s own activities e"g" operational and wor! instructions for the organiGation distribution of responsibilities and operations of the company" $F Duality files derived from the documents reports and chec! lists EformsF on actions relating to the product and documents delivered to the customer together with the product" 4"'8"$ .ecords relating to the company&s own operations In a welding company records are for e*ample the organiGational descriptionCchart responsibilities and authoriGations within the organiGation the equipment list and documents specified in ISO 3834#$"
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3'

These include instructions relating to document management and procedures for0 how perform certain operations references to standards if possible the person performing the operation the timing of the operation signing the completion of operation"
In addition to table $ the following records may be useful0 correspondence with the customer inquiries offersCtenders orders confirmations of orders documents and confirmations of orders relating to purchasing drawings approved subcontractors non#destructive and destructive testing procedures and reports procedures for acceptance of parent materials and transfer of mar!s material certificates 4"'8"3 Duality files regarding a specific product + contract product standard or law may require that certain quality records have to be delivered together with the product to the purchaser and in some cases also to the relevant authorities" Duality files should also be retained in order to demonstrate the achievement of the required quality and the efficient functioning of the quality procedures" The documents should be prepared at the stage of manufacture or inspection concerned and collected so that they can be collected immediately when the product has been completed" The welding coordinator or the person responsible for quality should chec! and approve the documents before sending them to the customer" The documents should be sufficiently clear accurate and easily identifiable as belonging to a specific product so that it can be proved afterwards that the requirements of manufacture and inspections have been fulfilled" The manufacturer files the documents in accordance with its own archiving procedures" +nother way of ensuring that the necessary documents are created on schedule is to have a production or quality plan covering the stages and operations involved in the product&s manufacture and inspection signed by the responsible person when the required actions have been completed" The documents specified in the contract shall be submitted together with the product" The documents to be delivered may include the following0 records of requirementCtechnical reviews productionCquality plan material certificates information on welding consumables
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3$

reports of material testing routing cards relating to inspection measurement and other test reports list of welding procedure specifications used list of qualified welders used heat treatment procedure specifications and reports records of repairs and non#conformance reports"
T(e 6eriods 3or re5en5ion o3 indi:idua. re0ords s(a.. =e de3ined and do0u-en5ed and 5(e re0ord (o.ders iden5i3ied2 4"'8"4 :ocument management The manufacturer should create an easily usable list#based or other equivalent procedure for document control in order to verify their validity and to prevent the use of invalid andCor outdated documents" The documents shall be provided with an identification number a revision number signature and date of approval" The persons to whom the documents have been delivered to shall be listed and at the same time it is ensured that all have the latest revised version at their disposal" The documents may be filed as a hard copy or in an electronic format for e*ample for '- years" The person who has approved the original document should also approve any changes made" The points changed are to be mar!ed in a suitable manner" 5 Need 3or 0er5i3i0a5ion
)ulfillment of the requirements of ISO 3834 can be demonstrated in different ways" Often the requirement may be a certification of the system" The company should be able to choose itself whether it wants certification to promote mar!eting to improve overall quality and efficiency and to increase the credibility of its operations from the customers& or sta!eholders& perspective"
There are several ways of showing the customer or a potential customer that the company&s welding quality requirements have been met" These are0 a method bilaterally agreed on between the customer and the company auditing by the customer auditing by a third party chosen by the customer" Duality is always a question of agreement between the customer and the supplier which does not necessarily require certification" 6 #do65ion o3 ISO 3+34 in a 0o-6an< The adoption of ISO 3834 in a company may for e*ample be carried out in as a project in three stages" #T 5(e 3irs5 s5a8e the company has to carry out a survey of the current situation" This stage should be performed with great care and sufficient time should be spent on it as it forms the basis for the success of the whole project" The current situation should be
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33
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e*amined as thoroughly and as truthfully as possible" It is human at this stage to NembellishO the actual situation in the company" Such embellishment however ma!es the actual advantage gained from the project smaller than e*pected" 3ery often only the requirements of the standard will be met but the possibilities for improving the quality and efficiency of the production will be lost already at the beginning of the project" In many cases the e*amination of the initial situation is useful if consultation with an outside e*pert is used because the e*pert has no need to describe the situation as better than it actually is" 5either is an outside e*pert subject to Nwor!place blindnessO which is only human for people who have wor!ed for a long time at the same wor!place" @hen real quality improvement is defined as the goal it is important to gain the commitment of personnel at all levels in the company&s hierarchy to the project" The e*ecutive management of the company shall give and demonstrate its full support for the project from the beginning to the end" This is supported by informing and training the personnel at the earliest possible stage" It has been found useful to arrange training of the stuff in connection with the survey of the current situation" The number of company&s staff products and company culture are important factors ma!ing the organiGing of a training event beneficial" Separate training events can be organiGed for clerical staff and welding personnel or all personnel groups can be gathered together in one event" The advantage of the first alternative is that the content of the training can be tailored accurately to meet the needs of target group" )or e*ample for welders the items of the standard on N/quipmentO N@elding activitiesO and N@elding consumablesO can be highlighted" )or the clerical staff it would be useful to concentrate for e*ample the item N.equirement and technical reviewsO" The advantage of a common training event organiGed for the whole personnel would be that it would be possible to e*amine matters from different perspectives" The various personnel groups would gain an overall picture of all the operations affecting quality management in welding as required by the standard" The personnel groups would get !nowledge of items dealt with in other groups& areas of responsibility and understand the actions required by themselves and others and the lin!ages and dependencies between them" The number of participants in the training events should be restricted to enable an open and controlled discussion of matters" In large enterprises it is better to arrange several events than to bring together the whole personnel or personnel group in one training event" There is no reason to underestimate the importance of training or information events because the basic requirement for a successful project is that the whole personnel is involved in developing the activities" The main objective of the first stage is to identify and record items needing improvement" +fter this stage it is often useful to update the project plan in order to ensure a realistic schedule for implementation" #5 5(e se0ond s5a8e on the basis of the initial survey an action plan shall be prepared for addressing the items needing development and the planned actions shall be performed" These actions may be split into separate tas!s for e*ample according to the
SI./T 0 4$$ 331 ,-' ---', # +2/ 1$4. # T3+ 0 ).$-4$$331,-'
34

list of contents in the standard or to the companies own quality manual" 9hronologically the separate tas!s may be carried out either simultaneously or successively" The method of implementation depends on the resources available for the project and how responsibilities are assigned in the company" +t latest at this stage of the project it is recommended to nominate a responsible personEsF for each item to be developed" Training of the company&s personnel continues at this stage" @hile the first stage mainly gives information on the content of ISO 3834 and the actions regarding needed procedures and documentation to meet the requirements at this stage the objective is focused on the technical content of actions and procedures" +ctivities and training given at this stage are to a large e*tent decisive as regards the technical and economic benefits that adopting ISO 3834 will bring the company" @hen the items according to ISO 3834 are used as a tool for measuring the quality producing capacity of the company and the wea!nesses and disadvantages found as a result of using the standard are addressed properly the productivity of welding can be improved and quality costs cut so that the e*penditure and effort put into the ISO 3834 project will be found as an e*cellent investment" The duration of the second stage depends very much on the siGe and initial situation of the company" If the company has a certified ISO ,--' quality system in place and it has for e*ample successfully manufactured standardiGed products it has in practice already had to operate according to many of the items of ISO 3834#$" .eadiness for certification can in this case be achieved quite quic!ly and with a very reasonable amount of wor!" The additional wor! may be limited to revising of a few operational procedures to bring them into the form required by ISO 3834" The wor! is considerably more demanding if the company does not have a certified quality system or a well documented quality management system has not been required for the products it manufactures especially as regards welding" The wor! of preparing procedures is in any case quite e*tensive even though an effort is made to minimiGe the number of procedures to what is appropriate" Time and resources shall also be reserved for understanding the purpose of the procedures and for learning the tas!s involved in practice and establishing them on all levels of production" Typically AH'8 months shall be reserved for the second stage" In order to achieve a timetable of A months the ISO 3834 wor! shall be done by teams of several EP 3F people simultaneously in the different areas of operations" If the implementation of the standard will be done in a team as small as possible Ee"g" in addition to normal wor!loadF the project will easily ta!e more than a year" The estimates above mainly concern companies with a wide production program" If the company manufactures a clearly limited range of products where the welding wor! is similar and the requirements are clearly established the timetable for adopting ISO 3834 may be much shorter" T(e 5(ird s5a8e involves chec!ing the functional effectiveness of the quality management system for welding and its compliance with standards so that any remaining disadvantages are found before the real audit by an e*ternal party" This Npre#auditO could
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31

be carried out by an e*pert in the project who has not participated in developing the procedures of the company concerned" The pre#audit could also be done by an outside e*pert familiar with ISO 3834" The idea here is to avoid a situation where a person could assess the results of his or her own wor!" +ny disadvantages found will of course be corrected after which the company can as! for an audit by an accredited certificating body" The end goal is an effectively functioning quality management system for welding and at this stage all the procedures will comply with the appropriate requirements according to ISO 3834" Pro=.e-s The most common problems occurring with the implementation of ISO 3834 are0 purchasing or ordering status of the responsible welding coordinator in the company handling of welding consumables following the welding procedure specifications validation of ammeters and voltmeters range of qualifications"
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342

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Con3ir-a5ionD Re-arEsF i3D re;uired
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+re the following technical aspects consideredK 2roduct standards Statutory and regulatory requirements +ny additional requirement determined by the manufacturer +ny additional requirement determined by the customer The capability of the manufacturer to meet the prescribed requirements Is the chec! of the requirements indicated and appropriately documented if necessaryK
=es 5o .emar!s0
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+re the following technical requirements chec!edK
'F $F
2arent materialEsF specification welded .emar!s0 joint properties Duality and acceptance requirements for welds 7ocation accessibility weld sequence E@elding 5:TF @elding procedures non# destructive testing procedures heat treatment Dualification of procedures 4raduation0 welding part $ 3 and 4 see table + of ISO 3834#'
. R .esult - R not applicable ' R met $ R partly met but still acceptable 3 R partly met but not acceptable 4 R not acceptable
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 Duality#control Inspection testing Sub# contracting 2ost#weld heat treatment Specific welding requirements Specific welding procedures Specifications regarding joint preparation and completed weld Is the chec! of the requirements indicated and appropriately documented if necessaryK e"g"" 9hec!list S$+-("&'RA('I&, =es 5o
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$ $
.emar!s0
+re sub#contractings performedK
Sub#contracting of welding wor!s =es C 5o Sub#contracting of inspection =es C 5o Sub#contracting of 5:T =es C 5o Sub#contracting of heat treatment =es C 5o Others0
'F $F
4raduation0 part $ 3 and 4 see table + of ISO 3834#' . R .esult - R not applicable ' R met $ R partly met but still acceptable 3 R partly met but not acceptable 4 R not acceptable
+re the followings items consi#dered by sub# contractingK
=es
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 :efinition of preconditions and criteria&s of selection of sub#contractors /nsuring of the necessary documents to the sub#contractor Observance of the relevant requirements according to ISO 3834 by the sub# contractor )ulfilling of the quality requirements by the sub#contractor Is the chec! of the requirements indicated and appropriately documented if necessaryK e"g"" Sub#contractor list Subcontractor audit plan
Con3ir-a5ionD Re-arEsF i3D re;uired .emar!s0
4 4
B B"$
W *DI&, - RS"&& * @elder and operators
B " $ ' 8
$ $
Is a sufficient number of wel# dersCoperators available and qualified by suitable qualification testsK
=es 5o Submit certificates or present them during the =es 5o

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Is the number of qualified weldersCoperators sufficientK +re the qualifications
1 1
B"3 B"3
@elding coordination personnel Is the welding coordination personnel competent and authoriGed to enable any necessary action to beK e"g" Organisation chart
'F $F
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 +re the tas!s and responsibilities definedK e"g" (atri* of responsibilities +re the competences for the review of requirements defined and is the welding coordinator integrated in the sense of /5 ISO '4B3'K Organisation chart :escription of position (atri* of competence Other proof E5omination
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+re the determinations suitableK
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:3S# S)ICI@/C/@/ number0 :3S# STCI@TC/@T number0 :3S# S)(CI@SC/@S number0 Other qualifications number0 Submit certificates or present them during the audit"
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Is the number sufficientK =es 5o +re the qualification suitableK =es 5o In case of other qualifications E:3S# S)IC/@/CI@/ :3S#STC/@TCI@T :3S# S)(C/@SCI@SF0 a separate professional interview is necessary covering the following items0 @elding 2rocesses @elding 9onsumables (aterials
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8 " $ ' 8 ,
$ $
B 8 B
Is the personnel sufficient qualified to perform non#destructive testingK Esee /5 ISO 3834#10 $--1 tables 3 and '-F
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=es 5o Submit certificates or
,"$
Is an actual list of essential equipment used for production and testing availableK 2ower sources and other machines /quipment for joint and surface preparation as well as for cutting including
=es 5o Submit the list or present it during the audit with details to0 (a*imum capacity of craneEsF
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 /quipment for preheating and post#heat treatment including temperature indicator >igs and fi*tures 9ranes and handling equipment used for the production 2ersonal protective equipment and other safety equipment directly associated with the applicable manufacturing process Ovens quivers etc" used for treatment of welding )acilities for surface Is the equipment adequate to the welding application concernedK Is the correct function of new or refurbished equipment verified before the initial operationK
Con3ir-a5ionD Re-arEsF i3D re;uired handle 9apability of mechanised or automatic welding equipment :imensions and ma*imum temperature of furnaces for heat treatment 9apacities of rolling bending and cutting equipment
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=es 5o =es 5o .emar!s0
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$ B , " 1 ' 8 , 'F $F
+re documented plans for the maintenance of equipment available including control of maintenance of the facilities used for chec!ing the relevant parameters of the welding specificationsK :o the plans cover all equipment which are essential for the quality of the componentsK 9ondition of guides in equipment for thermal
=es 5o .emar!s0 =es 5o .emar!s0

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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 mechanised fi*tures etc" 9ondition of ammeters voltmeters flow meters etc used for the operation of the welding equipment 9ondition of cables hoses connectors etc" 9ondition of control system in mechanised andCor automatic welding unit 9ondition of temperature# Is guaranteed that defective equipment is not usedK
=es 5o .emar!s0
' -
'-
W *DI&, A&D
R *A' D A('I!I'I S
' -
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Is a production planning carried out including the equipment foresight for use of manufacturing and testing Specification of the sequence by which the componentCconstruction shall be manufactured Identification of the individual processes required to manufacture the componentCconstruction .eference to the appropriate procedure specifications for welding and allied processes
=es 5o .emar!s0
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44
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 Order and timing in which the individual processes are to be performed Specification for inspection and testing including the involvement of any independent inspection body /nvironmental conditions Ee"g" protection from wind and rainF Identification by batches components or parts +llocation of qualifies personnel +rrangement for any production test +re the production plans suitable for the relevant application and do they contain all necessary informationK
=es 5o .emar!s0
' -
'"$ '8
' '
+re welding procedure specifications E@2SF for the welding procedures in use availableK +rc welding E/5 ISO '1A-,# 'F 4as welding E/5 ISO '1A-,#$F /lectron beam welding E/5 ISO '1A-,#3F 7aser beam welding E/5 ISO '1A-,#4F +rc stud welding E/5 ISO '4111F %y which method are these welding procedures qualifiedK Dualification by a welding
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 Dualification based on tested consumables E/5 ISO '1A'-F Dualification based on previous e*perience E/5 ISO '1A''F Dualification by adoption of a standard welding procedure E/5 ISO '1A'$F Dualification based on pre#production welding test E/5 ISO '1A'3F Others0 =es 5o =es 5o
' -
'-" 4
+re additional to the welding procedures specifications also wor! instructions usedK Is a procedure for establishing and control of relevant quality documents availableK 2rocedure for establishing and controlling of e"g"0 # @2S # @2D. # Inspection documents
' ' ' '-" 1
' '
' $
.emar!s0
' 3 ' 4 $ $
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W *DI&, ("&S$%A+* S +re responsibilities and procedures for control of welding consumables specifiedK e"g0 9onformity certificate Is batch testing of welding consumables requiredK =es 5o .emar!s0 =es 5o
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 +re procedures for storage handling and use of welding consumables produced and implementedK (oisture pic!# up O*idation :amage
Con3ir-a5ionD Re-arEsF i3D re;uired =es 5o .emar!s0
'1 '1
'$ '$
S'"RA, "# -AR &' %A' RIA*S Is the storage of the parent material Eincluding material supplied by the customerF performed in such a way that they are not be adversely affectedK +re measures and plans available for environmental influencesK +re tas!s and responsibilities for control of the storage of parent material specified and implemented in production Eidentification storage and handlingFK =es 5o .emar!s0
=es 5o .emar!s0
' 1 $ $
' $ ' 8
Is the mar!ingCidentification during the time of storing gua#ranteedK Type of mar!ing Inspection documents -"S'-W *D ) A' 'R A'% &' Is post#weld heat treatment performedK Ealso sub#contractingFK +re the responsibilities for the performance of post# weld heat treatment specifiedK
=es 5o .emar!s0 =es 5o E)urther questions are not applicableF =es 5o

4B
'A 'A
'3 '3
'A
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'F $F
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Con3ir-a5ionD Re-arEsF i3D re;uired .emar!s0 =es 5o .emar!s0
' A $ $
' 3 ' 8
Is post#weld heat treatment performed according to written instructionsK .elated to e"g"0 2arent material @elded joint 9omponent
' A $ $
' 3 ' 8
9an on the basis of the record the traceability of the performance of the post#weld heat treatment to the particular component be demonstratedK .ecording of the process parameter Ee"g" heat treatment recordF SiGe of the furnace 9onditions of supporting in
=es 5o .emar!s0
'B
'4
I&S- ('I"& A&D ' S'I&,
' B $ $
'4 "$ '8
+re inspection and testing before welding performed in accordance with the contactCrulesK Suitability and validity of welders and operators qualification certificates Suitability of the welding procedure specification Identity of parent material Identity of welding
=es 5o .emar!s0
'F $F
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 the welding procedure specification Suitability of wor!ing conditions +re inspection and testing during welding performed in accordance with the contractCrulesK /ssential welding parameters 2reheatingCinterpass temperature 9leaning and shape of runs and layers of weld metal %ac! gouging @eld sequence 9orrect use and handling of welding consumables
=es 5o .emar!s0
' B $ $
'4 "4 '8
+re inspection and testing after welding performed in accordance with the contactCrulesK %y visual testing %y non#destructive testing %y destructive testing )orm shape and dimension of the Is the status of inspection and testing given as appropriateK e"g"" +t the component In the routing cards
=es 5o .emar!s0
' B $ $
'4 "1 '8
=es 5o .emar!s0
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 +re measures implemented to handle items which are not conform to specified requirementsK Identification .esponsibilities .epair specificationCrepair .e# inspection (easures for avoiding recurrence +re non#conformance
Con3ir-a5ionD Re-arEsF i3D re;uired =es 5o .emar!s0
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(A*I+RA'I"& A&D !A*IDA'I"& "# % AS$RI&,. I&S- ('I"&

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',
'A
+re measuring inspection and testing equipment calibrated and validatedK /quipment 2rocedure .esponsibilities
=es 5o Submit a list or present it during the audit
$ $ $ '
'B
ID &'I#I(A'I"&
A&D 'RA( A+I*I'/I
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+re rules for identification and traceability during the manufacturing process availableK e"g" it can be required0 Identification of production plans Identification by routing cards Identification of weld locations
=es 5o .emar!s0
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9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 Identification of non# destructive testing procedures and personnel Identification of welding consumables Identification andCor traceability of the parent material Identification of location of repairs Identification of location of temporary attachments Traceability of fully mechanised and automatic welding units to specific welds Traceability of welder and operators to specific Q$A*I'/ R ("RDS
$$
'8
+re quality records available and for which time period are they retainedK Time period S 1 years .ecord of requirementCtechnical review (aterial inspection documents @elding consumables inspection documents @elding procedure specifications E@2SF /quipment maintenance records @elding procedure qualification records E@2D.F @elder or welder
=es 5o .emar!s0
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---
---
###
###
9ues5ions 5o 5(eD ;ua.i5< re;uire-en5sD a00ordin8 5o ISO 3+342 personnel certificates ;eat treatment specifications and records 5on#destructive and destructive testing procedures reports :imensional reports .ecords of repairs and non#conformance reports Other documents if required $S "# S'A&DARDS &"' ("! R D I& IS" 0102-3 :oes the manufacturer specify the use of standards different than those referred in ISO 3834#1K $S "# ') ( R'I#I(A' :oes the use of the certificate by the manufacturer give a true and accurate image of the manufacturer&s capability covered by the certificationK
=es 5o =es 5o .emar!s0
### ###
### ###
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Paris Nord 2 - 90 rue des Vanesses - BP 51362 - VILLEPINTE - 95942 ROISSY C P(one ) * 33 1 49 90 36 0+ 'a% ) * 33 1 49 90 36 +0 !E "#$LLE Cede% & 'R#NCE * 33 1 49 90 36 15 4EB Si5e ) (556)77///2ii/-iis2or8 * 33 1 49 90 36 ,9 E-ai. ) ii/0eo1/anadoo23r
#nne% B) E%a-6.e o3 a si-6.e 6ro0edure 3or ;ua.i3i0a5ion o3 /e.ders

S0o6e This procedure ensures that the welders have the required qualification 'ie.d o3 a66.i0a5ion This procedure concerns qualification of welders according to ISO ,A-AC/5 $8B#'" 9ua.i3i0a5ion 5es5in8 o3 /e.ders and e%a-ina5ion +ll welders perform qualification tests according to ISO ,A-AC/5 $8B#'" +nne* + includes a list of the qualification tests to be performed" )or e*amination chec! list 9 A"$ will be used" Tes5in8 The welding co#ordinator performs the visual testing according to ISO 'BA3B" +fter acceptance the test pieces will be sent to testing laboratory EInspection 7tdF for radiographic testing" Esee procedure % 1"3jF" 9ua.i5< re0ords The responsible welding co#ordinator files a data base including all weldersI certificates" The data base includes a list of welders their qualification and validity" Va.idi5< The welding co#ordinator signs the certificates every si* months" )or signing the welding foreman provides the welding co#ordinator with all necessary information concerning welding wor!" /very two years new qualification tests are carried out"
3F 4F
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Standard 3834 Si Audit Atasat

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International Institute of Welding A world of joining experience

International Institute of Welding

International Institute of Welding

4 4 1 A A B 8 ''' '4 'B ', ', $' $$ $3 $4 $1 $B equipment $, 33$ 33

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International Institute of Welding

International Institute of Welding

2ressure vessels E/5 '3441F

+t least ISO 3834#3

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International Institute of Welding

.ailway vehicles E/5 '1-81F

Off shore E5O.SO<F @ater tube boilers E/5 '$,1$#1F

The purpose of procedure is to0

International Institute of Welding

1 .eview of requirement review and technical review A Sub# contracting

International Institute of Welding

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International Institute of Welding

''"3 Stoc! list

'4 Inspection and testing

'1 5on#conformance and corrective actions

'A 9alibration and validation of measuring inspection and testing equipment

'B Identification and traceability

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International Institute of Welding

/*ample see anne* +

'8 2rocedure for preparing and filing of $Fquality records

'8 .ecord forms

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

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International Institute of Welding

International Institute of Welding

International Institute of Welding

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International Institute of Welding

@elding and related activities

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

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International Institute of Welding

Inspection and testing

International Institute of Welding

International Institute of Welding

+cceptance levels Ee"g" corresponding to quality levelsF

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

International Institute of Welding

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International Institute of Welding

#nne% #) 9ues5ionnaire 3or #udi5s a00ordin8 5o EN ISO 3+34-2)

/ample see anne +

W DI&, - RS"&& @elder and operators